Back to EveryPatent.com
United States Patent |
5,156,558
|
Belanger, Jr.
|
October 20, 1992
|
Horizontal mating connector
Abstract
An electrical connector includes terminals and receptacles mating at an
angle relative to the horizontal force applied to couple them. Keying
flanges mounted on a terminal housing slide along guide channels of a
receptacle frame in a first direction, and are then directed along keying
slots in a second direction, angularly related to the first direction, to
mate the terminals and receptacles mounted in the receptacle frame. The
connector is compact and may be assembled with application of a single
coupling force in one direction. The angular disposition of terminals and
receptacles provides improved resistance to uncoupling. A system of such
electrical connectors is provided, including means for preventing
cross-connection of unrelated circuits and components. Finally, a method
for interconnecting electrical circuits and components with such
electrical connectors is provided.
Inventors:
|
Belanger, Jr.; Thomas D. (Saline, MI)
|
Assignee:
|
Ford Motor Company (Dearborn, MI)
|
Appl. No.:
|
709462 |
Filed:
|
June 3, 1991 |
Current U.S. Class: |
439/376; 29/869 |
Intern'l Class: |
H01R 013/629 |
Field of Search: |
439/266,310,342,376,347,680
29/869
|
References Cited
U.S. Patent Documents
3020511 | Feb., 1962 | Raver | 439/376.
|
3869186 | Mar., 1975 | Teagno | 439/342.
|
4103983 | Aug., 1978 | Morrison et al. | 339/91.
|
4418975 | Dec., 1983 | O'Keefe II | 339/91.
|
4755906 | Jul., 1988 | Belanger, Jr. | 361/413.
|
4755907 | Jul., 1988 | Belanger, Jr. | 361/413.
|
4794488 | Dec., 1988 | Belanger, Jr. | 361/395.
|
4797784 | Jan., 1989 | Belanger, Jr. | 361/395.
|
4797786 | Jan., 1989 | Belanger, Jr. | 361/419.
|
4821149 | Apr., 1989 | Belanger, Jr. | 361/395.
|
4903168 | Feb., 1990 | Belanger, Jr. | 361/413.
|
Primary Examiner: Desmond; Eugene F.
Attorney, Agent or Firm: Abolins; Peter, Mollon; Mark
Claims
What is claimed is:
1. An electrical connector comprising:
a terminal housing including a plurality of first electrical terminal
elements mounted within said terminal housing;
a receptacle frame for receiving said terminal housing and including a
plurality of second electrical terminal elements mounted within said
receptacle frame, said plurality of second electrical terminal elements
adapted to couple with said plurality of first electrical terminal
elements; and
guidance means for guiding said terminal housing received in said
receptacle frame initially in a first direction of movement, and for
guiding said plurality of first electrical terminal elements in a second
direction of movement angularly oriented relative to said first direction
at an acute angle to couple along said second direction of movement with
said plurality of second electrical terminal elements.
2. An electrical connector as recited in claim 1 wherein said first
electrical terminal elements comprise electrical terminal pins, and said
second electrical terminal elements comprise electrical terminal pin
receptacles for receiving said terminal pins.
3. An electrical connector as recited in claim 1 wherein said first
electrical terminal elements comprise electrical terminal pin receptacles,
and said second electrical terminal elements comprise electrical terminal
pins.
4. An electrical connector as recited in claim 1 further comprising force
applying means attached to said terminal housing and said receptacle frame
for coupling said first and second electrical terminal elements, said
force applying means positioned such that force is applied to said
terminal housing in said first direction.
5. An electrical connector as recited in claim 4 wherein said force
applying means further provides for uncoupling said first and second
electrical terminal elements.
6. An electrical connector as recited in claim 4 wherein said force
applying means consists of a cam lever operable mounted on said terminal
housing and at least one cam attached to said receptacle frame.
7. An electrical connector comprising:
a terminal housing including a plurality of first electrical terminal
elements mounted within said terminal housing;
a receptacle frame for receiving said terminal housing and including a
plurality of second electrical terminal elements mounted within said
receptacle frame, said plurality of second electrical terminal elements
adapted to couple with said plurality of first electrical terminal
elements; and
guidance means for guiding said terminal housing received in said
receptacle frame initially in a first direction of movement, and for
guiding said plurality of first electrical terminal elements in a second
direction of movement angularly oriented relative to said first direction
at an acute angle to couple with said plurality of second electrical
terminal elements; and
wherein said plurality of first electrical terminal elements and said
plurality of second electrical terminal elements are mounted at angles
generally parallel to said second direction.
8. An electrical connector comprising:
a terminal housing including a plurality of first electrical terminal
elements mounted within said terminal housing;
a receptacle frame for receiving said terminal housing and including a
plurality of second electrical terminal elements mounted within said
receptacle frame, said plurality of second electrical terminal elements
adapted to couple with said plurality of first electrical terminal
elements; and
guidance means for guiding said terminal housing received in said
receptacle frame initially in a first direction of movement, and for
guiding said plurality of first electrical terminal elements in a second
direction of movement angularly oriented to relative to said first
direction to couple with said plurality of second electrical terminal
elements, said guidance means comprising:
a plurality of keying flanges extending from said terminal housing;
a plurality of guide channels in said receptacle frame for guiding said
plurality of keying flanges in said first direction;
at least one first sloped wall positioned at the end of at least one of
said plurality of guide channels for directing the travel of said
plurality of keying flanges; and
a plurality of keying slots in said receptacle frame to permit said
plurality of keying flanges to travel in said second direction generally
parallel to said at least one first sloped wall.
9. An electrical connector as recited in claim 8 wherein said plurality of
keying slots have side walls sloped at an angle relative to said plurality
of guide channels.
10. An electrical connector as recited in claim 9 wherein the angle at
which said side walls are sloped is substantially equal to the angle of
said at least one sloped wall.
11. An electrical connector as recited in claim 8 wherein said plurality of
guide channels have walls extending substantially perpendicularly into
said receptacle frame.
12. An electrical connector as recited in claim 8 wherein said guidance
means further comprises:
a plurality of trailing down ramps extending from side faces of said
terminal housing; and
at least one second sloped wall formed in said plurality of guide channels
sloped relative to said plurality of trailing down ramps such that said
plurality of trailing down ramps traveling along said at least one second
sloped wall further align and support the intermating of said pluralities
of first and second electrical terminal elements.
13. An electrical connector as recited in claim 8 wherein said plurality of
keying flanges extend substantially perpendicularly from said terminal
housing.
14. An electrical connector comprising:
a terminal housing including a plurality of first electrical terminal
elements mounted within said terminal housing, wherein:
said plurality of first electrical terminal elements are disposed in a
plurality of insertable housing blocks; and
said terminal housing further comprises means for retaining said plurality
of housing blocks;
a receptacle frame for receiving said terminal housing and including a
plurality of second electrical terminal elements mounted within said
receptacle frame, said plurality of second electrical terminal elements
adapted to couple with said plurality of first electrical terminal
elements; and
guidance means for guiding said terminal housing received in said
receptacle frame initially in a first direction of movement, and for
guiding said plurality of first electrical terminal elements in a second
direction of movement angularly oriented relative to said first direction
at an acute angle to couple with said plurality of second electrical
terminal elements.
15. An electrical connector comprising:
a terminal housing including a plurality of first electrical terminal
elements mounted within said terminal housing, wherein:
at least one of said plurality of first electrical terminal elements are
disposed in at least one insertable housing block; and
said terminal housing further comprises means for retaining said at least
one housing block, said means for retaining comprising at least one track
in said terminal housing adapted to slidably receive at least one rail
extending from ones of said housing blocks;
a receptacle frame for receiving said terminal housing and including a
plurality of second electrical terminal elements mounted within said
receptacle frame, said plurality of second electrical terminal elements
adapted to couple with said plurality of first electrical terminal
elements; and
guidance means for guiding said terminal housing received in said
receptacle frame initially in a first direction of movement, and for
guiding said plurality of first electrical terminal elements in a second
direction of movement angularly oriented relative to said first direction
at an acute angle to couple with said plurality of second electrical
terminal elements.
16. An electrical connector comprising:
a terminal housing including a plurality of first electrical terminal
elements mounted within said terminal housing;
a receptacle frame for receiving said terminal housing and including a
plurality of second electrical terminal elements mounted within said
receptacle frame, said plurality of second electrical terminal elements
adapted to couple with said plurality of first electrical terminal
elements, wherein:
said plurality of second electrical terminal elements are disposed in a
plurality of insertable frame blocks; and
said receptacle frame further comprises means for retaining said plurality
of frame blocks; and
guidance means for guiding said terminal housing received in said
receptacle frame initially in a first direction of movement, and for
guiding said plurality of first electrical terminal elements in a second
direction at an acute angle to couple with said plurality of second
electrical terminal elements.
17. An electrical connector comprising:
a terminal housing including a plurality of first electrical terminal
elements mounted within said terminal housing;
a receptacle frame for receiving said terminal housing and including a
plurality of second electrical terminal elements mounted within said
receptacle frame wherein:
said plurality of second electrical terminal elements are adapted to couple
with said plurality of first electrical terminal elements;
at least one of said plurality of second electrical terminal elements are
disposed in at least one insertable frame block; and
said receptacle frame further comprises means for retaining said at least
one frame block, said means for retaining comprising at least one track in
said receptacle frame adapted to slidably receive at least one rail
extending from ones of said frame blocks; and
guidance means for guiding said terminal housing received in said
receptacle frame initially in a first direction of movement, and for
guiding said plurality of first electrical terminal elements in a second
direction of movement angularly oriented to relative to said first
direction to couple with said plurality of second electrical terminal
elements.
18. A system for making electrical connections comprising:
at least two electrical connectors for making electrical connections, each
of said at least two electrical connectors comprising:
a terminal housing including a plurality of first electrical terminal
elements mounted within said terminal housing;
a receptacle frame for receiving said terminal housing and including a
plurality of second electrical terminal elements mounted within said
receptacle frame for receiving said plurality of first electrical terminal
elements, said plurality of second electrical terminal elements adapted to
couple with said plurality of first electrical terminal elements; and
guidance means for guiding said terminal housing received in said
receptacle frame initially in a first direction of movement, and for
guiding said plurality of first electrical terminal elements in a second
direction of movement angularly oriented relative to said first direction
to couple with said plurality of second electrical terminal elements; and
wherein said guidance means of said two or more electrical connectors are
substantially similar, but differ in at least one dimensional relationship
to prevent cross-connection of said terminal housings and receptacle frame
from different ones of said at least two electrical connectors.
19. A system as recited in claim 18 wherein said second direction of
movement is angularly oriented relative to said first direction at an
acute angle.
20. A system as recited in claim 18 wherein said guidance means of each of
said two or more electrical connectors each comprises:
a plurality of keying flanges extending from said terminal housing;
a plurality of guide channels in said receptacle frame for guiding said
plurality of keying flanges in said first direction;
at least one first sloped wall positioned at the end of said plurality of
guide channels for directing the travel of said plurality of keying
flanges; and
a plurality of keying slots in said receptacle frame to permit said
plurality of keying flanges to in said second direction generally parallel
to said at least one first sloped wall.
21. A system as recited in claim 20 wherein, to prevent cross-connection of
said two or more electrical connectors, at least one dimension of said
plurality of keying flanges and the corresponding dimensions of said
plurality of guide channels and said plurality of keying slots in each of
said at least two electrical connectors are different, such that selected
keying flanges of one terminal housing are adapted to be received only in
corresponding guide channels on one receptacle frame.
22. A system as recited in claim 20 wherein, to prevent cross-connection of
said two or more electrical connectors, the spacing between said at least
one first sloped wall and at least one of said plurality of keying slots
and the corresponding lengths of said plurality of keying flanges in ones
of said two or more electrical connectors are different, such that
selected keying flanges of one terminal housing are adapted to be guided
only into corresponding keying slots of one receptacle frame.
23. A system as recited in claim 20 wherein:
in each of said at least two electrical connectors, said plurality of
keying slots have at least one side wall sloped at a control angle
relative to said plurality of guide channels and substantially parallel to
said second direction;
in each of said at least two electrical connectors, said plurality of first
electrical terminal elements and said plurality of second electrical
terminal elements corresponding therewith are mounted at angles generally
parallel to said second direction; and
to prevent cross-connection of said two or more electrical connectors, said
control angle and said second direction in each of said at least two
electrical connectors are different, such that selected first electrical
terminal elements of one terminal housing will only couple in said second
direction with corresponding second electrical terminal elements of one
receptacle frame.
24. A system as recited in claim 20 wherein, to prevent cross-connection of
said two or more electrical connectors, the spacing between adjacent
keying flanges extending from said terminal housing and the corresponding
spacing of adjacent keying slots in said receptacle frame in each of said
two or more electrical connectors is different, such that selected keying
flanges of one terminal housing are adapted to be guided only into
corresponding keying slots of one receptacle frame.
25. A system as recited in claim 20 wherein, to prevent cross-connection of
said two or more electrical connectors, the angle at which said keying
flanges extend from said terminal housing and the corresponding angle at
which said guide channels and said keying slots are provided in said
receptacle frame in each of said two or more electrical connectors are
different, such that selected keying flanges of one terminal housing are
adapted to be received only in corresponding guide channels of one
receptacle frame.
26. A system for making electrical connections comprising:
at least two electrical connectors for making electrical connections, each
of said at least two electrical connectors comprising:
a terminal housing including a plurality of first electrical terminal
elements mounted within said terminal housing;
a receptacle frame for receiving said terminal housing and including a
plurality of second electrical terminal elements mounted within said
receptacle frame for receiving said plurality of first electrical terminal
elements, said plurality of second electrical terminal elements adapted to
couple with said plurality of first electrical terminal elements; and
guidance means for guiding said terminal housing received in said
receptacle frame initially in a first direction of movement, and for
guiding said plurality of first electrical terminal elements in a second
direction of movement angularly oriented relative to said first direction
at an acute angle to couple with said plurality of second electrical
terminal elements; and
wherein said guidance means of said two or more electrical connectors are
substantially similar, and to prevent cross-connection of said two or more
electrical connectors, the positions of said first electrical terminal
elements and corresponding second electrical terminal elements mounted in
ones of said at least two connectors are different in each of said two or
more connectors, such that selected first electrical terminal elements of
one terminal housing will only couple in said second direction with
corresponding second electrical terminal elements of one receptacle frame.
27. A method for making electrical connections comprising the steps of:
inserting a terminal housing including a plurality of first electrical
terminal elements in a first direction into a receptacle frame including a
plurality of second electrical terminal elements matable therewith;
guiding said terminal housing within said receptacle frame along a path
including a portion angularly oriented in a second direction relative to
said first direction, such that said plurality of first electrical
terminal elements align with said plurality of second electrical terminal
elements as said terminal housing moves along said angularly oriented
portion of said path; and
applying a coupling force in a direction generally parallel to said first
direction to further move said terminal housing in said second direction
along said angularly oriented portion of said path and intermate said
pluralities of first and second electrical terminal elements.
28. A method as defined by claim 27, wherein said step of applying a
coupling force is accomplished by operating a force applying means to
apply a force in said first direction which further moves said terminal
housing in said second direction to intermate said pluralities of first
and second electrical terminal elements.
29. A method as defined by claim 24, wherein said step of guiding is
further accomplished by a plurality of trailing down ramps extending from
said terminal housing and at least one second sloped wall formed in said
plurality of guide channels angled relative to said plurality of trailing
down ramps such that said plurality of trailing down ramps further align
and support the intermating of said pluralities of first and second
electrical terminal elements.
30. A method for making electrical connections comprising the steps of:
inserting a terminal housing including a plurality of first electrical
terminal elements in a first direction into a receptacle frame including a
plurality of second electrical terminal elements matable therewith;
guiding said terminal housing within said receptacle frame along a path
including a portion angularly oriented in a second direction relative to
said first direction, such that said plurality of first electrical
terminal elements align with said plurality of second electrical terminal
elements along said angularly oriented portion, said step of guiding
comprising:
sliding a plurality of keying flanges extending from said terminal housing
in said first direction along a plurality of guide channels formed in said
receptacle frame; and
directing said plurality of keying flanges in said second direction along a
plurality of keying slots formed in said receptacle frame, by contacting
at least one first sloped wall at the end of said plurality of guide
channels; and
applying a coupling force generally parallel to said first direction to
intermate said pluralities of first and second electrical terminal
elements along a path generally parallel to said second direction.
31. A method as defined by claim 30, wherein said step of directing directs
said keying flanges along a plurality of keying slots having at least one
side wall angled relative to said plurality of guide channels and
substantially parallel to said second direction.
32. A method as defined by claim 30, wherein said step of sliding slides
said keying flanges along a plurality of guide channels having walls
substantially perpendicular to said receptacle frame.
33. A method as defined by claim 30, wherein said plurality of keying
flanges are substantially perpendicular to said terminal housing.
34. A method as defined by claim 27 wherein said first and second terminal
elements extend from said terminal housing and said receptacle frame
generally parallel to said second direction, and wherein:
said step of guiding includes aligning ones of said plurality of first
terminal elements end to end with ones of said plurality of second
electrical terminal elements in ones of a plurality of paths generally
parallel to said second direction; and
said step of applying a coupling force intermates said pluralities of first
and second terminal elements along said plurality of paths generally
parallel to said second direction.
35. A method as defined by claim 30, wherein said force applying means
comprises a cam lever operably mounted on said terminal housing and at
least one cam attached to said receptacle frame.
Description
BACKGROUND OF THE INVENTION
The present invention relates generally to electrical connectors, and more
particularly, to a connector having terminals and receptacles mating at an
angle relative to the horizontal force applied to assemble the connector.
Plug-in connectors have become widely known and used in the electronics
industry for interconnecting electrical circuits and circuit components.
For example, Morrison et al, U.S. Pat. No. 4,103,983 slidably connects
electronic equipment to a mounting with pin and socket connectors.
O'Keefe, II, U.S. Pat. No. 4,418,975, slidably couples a plurality of
spaced, offset rows of connector blocks to a corresponding plurality of
terminal pads located on electronic equipment. Belanger, Jr., in U.S. Pat.
Nos. 4,755,906, 4,755,907 and 4,903,168, interconnects electrical
substrates to carrier substrates. Tabs on the electrical substrate are
guided by sloped channels in the carrier substrate to bring horizontal
pins and sockets on the respective substrates into alignment for
interconnection. In each case, the mating connector elements of Morrison
et al, O'Keefe II, and Belanger, Jr. are coupled along a line parallel to
the coupling force.
Such plug-in connectors are needed so that a plurality of connections may
be made quickly without tedious and time consuming hardwiring, so
connectors may be readily connected and disconnected, and so that compact
configurations are made possible where space is at a premium. New
structures are therefore continually sought to satisfy these needs and
provide improved means for interconnecting electrical circuits and
components.
SUMMARY OF THE INVENTION
This need is met by the present invention in which an improved, compact
connector includes mating first and second electrical terminal elements,
such as terminal pins and terminal pin receptacles, disposed at an angle
relative to the direction in which coupling forces are applied. The
connector includes a terminal housing which may be slidably inserted into
a receptacle frame upon the application of a coupling force in a single
direction and with a single motion. The terminal housing has a plurality
of keying flanges extending laterally therefrom which slide into
corresponding guide channels in the receptacle frame. As the terminal
housing is inserted into the receptacle frame, it encounters at least one
first sloped wall positioned at an end of the guide channels. The first
sloped wall directs the keying flanges of the terminal housing into a
plurality of keying slots, displacing the housing at an angle relative to
the guide channels, and aligning the mating terminal pins and terminal pin
receptacles for coupling. In addition, trailing down ramps may be provided
on the terminal housing to further maintain the parallel relation and
alignment between the terminal housing and the receptacle frame as the
terminal pins and terminal pin receptacles are intermated.
The angled position of the terminal pins and terminal pin receptacles
permits a more compact design, and requires higher coupling and uncoupling
forces than connectors which mate in a direction parallel to the applied
coupling force. The compact design tends to be flatter and shorter which
makes the connector of the present invention well suited for use in
automotive applications, such as in dashboards, where space is limited.
Further, a more secure connection results which resists accidental
disconnection, without need for additional fasteners. Even though the
keying flanges, guide channels and keying slots guide the terminal housing
along an angled path to couple the terminal pins and terminal pin
receptacles at an angle to the coupling force, coupling and uncoupling
forces need to be applied only in a single direction.
Additional features may be provided in the connector of the present
invention. Force applying means may be included to assist in coupling and
uncoupling the terminal housing and receptacle frame. Further, the
terminal pins and terminal pin receptacles may be assembled in groups on
one or more removable housing blocks or frame blocks, to make the
connector more versatile, facilitate production, facilitate attachment of
wires or components to terminal pins or terminal pin receptacles, permit
interchange of housing blocks or frame blocks, and the like. It is
understood that the terminal pins and terminal pin receptacles may be
included in either the terminal housing or in the receptacle frame, as may
suit the application.
In a further aspect of the present invention, a system including two or
more connectors is provided for connecting a plurality of electrical
circuits in accordance with the present invention. The system includes
means for preventing inadvertent cross-connection between unrelated
connector terminal housings and receptacle frames as a safety feature
where a plurality of connectors are required. Such means include producing
the terminal housings with keying flanges having different dimensions, and
providing the receptacle frames with guide channels having corresponding
dimensions. Similarly, the angle at which at least one first sloped wall
at the end of a guide channel and the angle at which the side walls of the
keying slots are sloped may be varied, so that the corresponding angles on
the keying flanges prevent their being directed down the keying slots of
non-mating receptacle frames. Means for preventing cross-connection may
further include varying the spacing between the keying slots and the end
of the guide channels, or varying the spacing between the keying slots
themselves. The corresponding locations of keying flanges on respective
terminal housings would prevent the cross-connection of unrelated terminal
housings and receptacle frames.
Finally, a method for interconnecting electrical circuits is provided in
which a terminal housing having first angularly oriented electrical
terminal elements is inserted into a receptacle frame having second
angularly oriented electrical terminal elements, and guided within the
receptacle frame to align and intermate the first and second electrical
terminal elements along the angular orientation. In accordance with the
method, the angular orientation is at an angle to the applied
interconnecting force.
It is therefore a feature of the present invention to provide a connector
for interconnecting electrical circuits wherein terminal pins and terminal
pin receptacles are disposed and interconnected to one another in angular
relation to the applied coupling force. It is another feature of the
present invention to provide a compact, secure connector. A further
feature of the present invention is that such a connector requires a force
directed in a single direction for insertion and coupling of mating parts.
Yet another feature of the present invention is to provide a system for
interconnecting a plurality of electrical circuits with two or more
connectors which have means for preventing cross-connection. Finally, a
feature of the present invention is to provide a method for
interconnecting electrical circuits. These and other features of the
present invention will be apparent from a review of the detailed
description taken with the drawing figures included herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of the connector of the present
invention prior to assembly.
FIG. 2 is a top view of the terminal housing of the present invention.
FIG. 3 is a cross-sectional view of the terminal housing of FIG. 2 taken
along section line 3--3 of FIG. 2.
FIG. 4 is a top view of the receptacle frame of the present invention.
FIG. 5 is a cross-sectional view of the receptacle frame of the present
invention taken along section line 5--5 of FIG. 4.
FIG. 6 is an exploded perspective view of alternative embodiment of the
terminal housing of the present invention.
FIG. 7 is an exploded perspective view of an alternative embodiment of the
receptacle frame of the present invention.
FIG. 8 is a schematic perspective view of the connector of the present
invention and force applying means for inserting the terminal housing into
the receptacle frame of the connector.
FIG. 9 is a schematic perspective view of the connector of the present
invention prior to assembly showing means for preventing cross-connection.
FIGS. 10A and 10B, 11A and 11B, and 12A and 12B are cross-sectional views
of the receptacle frame of the present invention taken along section line
10--10 of FIG. 4 and showing means for preventing cross-connection.
FIG. 13 is a cross-sectional view of the terminal housing of FIG. 2 taken
along section line 3--3 of FIG. 2, and a cross-sectional view of the
receptacle frame of the present invention taken along section line 5--5 of
FIG. 4, both in an alternative embodiment, showing means for preventing
cross-connection.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, in accordance with the present invention, a connector
10 is provided having a terminal housing 12 and receptacle frame 14.
Terminal housing 12 is slidably insertable into receptacle frame 14 upon
application of a coupling force in a single direction with a single
motion, as indicated at 16.
Guidance means for coupling terminal housing 12 and receptacle frame 14
include a plurality of keying flanges 18 extending from terminal housing
12 which slide into a plurality of guide channels 20 provided in
receptacle frame 14. With reference to FIGS. 1 and 5, at least one first
sloped wall 22, also referred to as a down ramp, is provided at the end of
guide channels 20 to direct keying flanges 18 into a plurality of keying
slots 24. Keying slots 24 define a guide key 26, and preferably include
one or more side walls 28 sloped at a control angle 30, shown as an acute
angle measured relative to guide channels 20 in FIG. 5. Control angle 30
is, preferably, substantially equal to the slope of first sloped wall 22.
Referring to FIGS. 1, 2 and 5, in addition, one or more trailing down ramps
32 may be provided on terminal housing 12 and at least one second sloped
wall 42 may be formed in guide channels 20 to assist in maintaining the
generally parallel relationship and alignment between terminal housing 12
and receptacle frame 14. Trailing down ramps 32 and at least one second
sloped wall 42 preferably include surfaces sloped at an angle equal to the
control angle 30, and provide a second contact point in addition to
contact between the keying flanges 18 and the first sloped wall 22 to
direct the keying flanges 18 into the keying slots 24. One or more of the
keying flanges 18 may also include surfaces sloped at an angle equal to
control angle 30, to enhance control of keying flanges 18 in keying slots
4. Where first and second sloped walls 22, 42, side walls 8, one or more
surfaces of keying flanges 18, trailing down ramp 32, terminal pins 34 and
terminal pin receptacles 36 are sloped at substantially the control angle
30, a plurality of surfaces in generally parallel relationship result
which align and guide the mating of terminal pins 34 and terminal pin
receptacles 36.
Preferably, as shown in FIGS. 1, 2 and 9, keying flanges 18 extend
substantially perpendicular to the side faces 44a, 44b of terminal housing
12. In turn, as shown in FIGS. 1, 5 and 9, guide channels 20 preferably
have guide channel walls 46 substantially perpendicular to inner walls
48a, 48b of receptacle frame 14. Alternatively, keying flanges 18 and
corresponding guide channel walls 46 may be angled relative to side faces
44a, 44b and inner walls 48a, 48b, respectively, as shown in FIG. 9, but
such is not preferred.
Terminal housing 12 and receptacle frame 14 include mating first and second
electrical terminal elements, respectively, disposed at an angle relative
to the direction in which a coupling force is applied. As shown best in
FIGS. 3-5, first electrical terminal elements are preferably electrical
terminal pins 34, and second electrical terminal elements are preferably
electrical terminal pin receptacles 36. While it is preferred to provide
terminal pins 34 in terminal housing 12 and terminal pin receptacles 36 in
receptacle frame 14, their positions may be reversed. Preferably, terminal
pins 34 and terminal pin receptacles 36 are disposed at an angle equal to
control angle 30, preferably a 45 degree angle relative to guide channels
20, and are mounted so as to include mating seating surfaces 38 and 40,
respectively. Terminal pins 34 and terminal pin receptacles 36 may include
crimp connections or other known means to connect wiring or electrical
components to terminal pins and terminal pin receptacles.
The angled positions of terminal pins 34 and terminal pin receptacles 36
are shown in FIGS. 1, 3, 5-7, 9 and 13. The angled positions permit a more
compact, flatter and shorter, overall connector design, and require higher
coupling and uncoupling forces than connectors which mate in a direction
parallel to the applied coupling force. As such, a more secure connection
results which resists accidental disconnection without need for additional
fasteners.
Shown in FIG. 8, a force applying means may be further included in the
present invention to assist in coupling and uncoupling the terminal
housing and receptacle frame. The force applying means is preferably a cam
lever mechanism 60, such as shown, which may be used for coupling,
uncoupling or both. Cam lever mechanism 60 includes a cam lever 62
operably mounted on terminal housing 12, and both a coupling cam 64 and an
uncoupling cam 66 attached to receptacle frame 14 against which cam lever
62 may act to apply coupling and uncoupling forces, respectively. Where
coupling and uncoupling cams 64, 66 are provided, cam lever mechanism 60
also serves to fasten terminal housing 12 to receptacle frame 14, adding
an additional degree of security to the connection.
As further representatively shown in FIG. 8, terminal receptacle frame 14,
or, alternatively, terminal housing 12, or both, may be attached directly
to an electrical module or component 68, rather than connecting to a
wiring harness or lead wires 70, 72 of a plurality of circuits, as
representatively shown in FIGS. 3, and 5-7.
FIG. 8 also shows keying flanges 18 disposed in their final positions in
keying slots 24 with terminal pins 34 and terminal pin receptacles 36
intermated.
As shown in FIGS. 6 and 7, in an alternative embodiment of terminal housing
12 and receptacle frame 14, terminal pins 34 and terminal pin receptacles
36 may be assembled in groups of one or more on removable housing blocks
50 or frame blocks 52. As representatively shown, housing blocks 50 are
assembled into terminal housing 12 by longitudinally dividing the terminal
housing 12 into first and second portions 12a and 12b, inserting housing
blocks rails 54 along tracks 56 in first portion 12a, sliding second
portion 12b over the remaining portion of housing blocks 50, and securing
first and second portions 12a and 12b with fasteners 58, such as screws.
Assembly of frame blocks 52 is achieved in like fashion, longitudinally
dividing receptacle frame into first and second portions 14a and 14b, as
shown in FIG. 7, where like numbers refer to like elements.
This alternative embodiment makes connector 10 more versatile and adaptable
for various applications. As well, the alternative embodiment can
facilitate certain production techniques, for example, hardwiring of the
terminal pins 34 or terminal pin receptacles 36, and permits user-oriented
benefits, such as interchange or replacement of one block with another for
repair or testing. It is understood that terminal pins 34 and terminal pin
receptacles 36 may be included in either the terminal housing 12 or
receptacle frame 14, as may suit the application. It is further understood
that the alternative embodiment of FIGS. 6 and 7 is representative of
various assembly arrangements which are possible to provide angularly
disposed electrical terminal elements on removable blocks in terminal
housing 12 and receptacle frame 14.
All parts of connector 10 of the present invention are made of conventional
materials, and may be attached by means known in the art. Terminal housing
12 and terminal receptacle frame 14 are preferably made of hard plastics,
as are known in the art.
In a further aspect of the present invention, a system including two or
more connectors 10 for connecting a plurality of electrical circuits may
be provided. Each of the two or more connectors 10 have first and second
electrical terminal elements disposed at an angle in accordance with the
present invention. As a safety feature, the system includes means for
preventing inadvertent cross-connection between unrelated terminal
housings 12 and receptacle frames 14 of different connectors 10.
Referring to FIG. 9, such means for preventing cross-connection includes
producing the terminal housings 12 with keying flanges 18 having different
dimensions, e.g. different thicknesses, lengths or widths, and providing
mating receptacle frames 14 with corresponding guide channel dimensions.
As also shown in FIG. 9, another means for preventing cross-connection
includes changing the angle at which keying flanges 18 extend from the
side faces 44a, 44b of terminal housing 12 and changing the corresponding
angle at which guide channels 20 are provided along inner walls 48a, 48b
of receptacle frame 14.
Still other means for preventing cross-connection, shown in FIGS. 10A and
10B, include providing different control angles 30 in different connectors
10 of the system. The control angles 30a and 30b in receptacle frames 14a
and 14b, respectively, differ from each other and, thus, vary the angle at
which other elements are correspondingly disposed. Thus, for example, the
angle of the at least one first sloped wall 22, and the substantially
equal angle of one or more side walls 28 of keying slots 24, and the at
least one second sloped wall 42 all vary between FIG. 10A and FIG. 10B. As
representatively shown, terminal housing 12a may thereby couple with
receptacle frame 14a, but not receptacle frame 14b. Further, as shown in
FIGS. 11A and 11B, the spacing between keying slots 24 and the end of
guide channels 20 at sloped wall 42 may be different to prevent
cross-connection. Thus, as representatively shown, terminal housing 12c
mates with terminal receptacle 14c, but not with terminal receptacle 14d.
Finally, as shown in FIGS. 12A and 12B, the spacing between keying slots
24, i.e. the size of guide key 26, may be different in different
connectors 10, as representatively shown with receptacle frames 14e and
14f, to prevent cross-connection.
As well, as representatively shown in FIG. 13, because a plurality of
terminal pins 34 and terminal pin receptacles 36 are provided in each
connector 10, the various electrical circuits to be attached may be
connected to selected terminal pins 34 and terminal pin receptacles 36 in
a pattern which would prevent inadvertent cross-connection even if
identical connectors 10 are used. Thus, cross-connection between wired
terminal pins 34 in terminal housing 12g and wired receptacles in
receptacle frame 14h would be avoided.
Further in this regard, as shown in FIG. 13, in a system of two or more
connectors 10 made in accordance with the alternative embodiment of FIGS.
6 and 7, where removable housing blocks 50 and frame blocks 52 are
provided in connectors 10, means for preventing cross-connection of
unrelated circuits further include selectably inserting rows of housing
blocks 50 and frame blocks 52 in terminal housings 12 and receptacle
frames 14. Such blocks are so located that a group of terminal pins 34 and
a group of terminal pin receptacles 36 will be aligned only when mating
terminal housings 12 and receptacle frames 14 are coupled. This means for
preventing cross-connection may be understood by reference to FIG. 13,
where housing blocks 50 and frame blocks 52, shown in phantom, have been
removed so that terminal housing 12g and receptacle frame 14h may not be
cross-connected.
In a still further aspect of the present invention, a method for
interconnecting electrical circuits with a connector 10 of the present
invention is provided. In accordance with the method, a connector 10 made
in accordance with the present invention is assembled to connect
electrical circuits or components. Terminal housing 12, having a plurality
of first electrical terminal elements, is inserted into receptacle frame
14, having a plurality of second electrical terminal elements matable
therewith. Terminal housing 12 is next guided within receptacle frame 14
to align the pluralities of first and second electrical terminal elements.
Finally, the pluralities of first and second electrical terminal elements
are intermated along a plane angularly oriented to an applied coupling or
interconnecting force.
The step of guiding terminal housing 12 within receptacle frame 14 includes
first sliding a plurality of keying flanges 18 extending from terminal
housing 12 in a first direction along a plurality of guide channels 20
formed in receptacle frame 14, and then directing the plurality of keying
flanges 18 in a second direction along keying slots 24 formed in the
receptacle frame by contacting at least one first sloped wall 22 at the
end of guide channels 20. The step of sliding is preferably performed in a
direction substantially parallel to the applied coupling or
interconnecting force, while the step of directing the plurality of keying
flanges 18 along keying slots 24 directs keying flanges 18 in a second
direction angled relative to the applied coupling or interconnecting
force.
The step of directing keying flanges 18 along keying slots 24 may be
further accomplished by contacting one or more trailing down ramps 32,
which extend from side faces 44a, 44b of terminal housing 12, with at
least one second sloped wall 42 formed in guide channels 20, to align and
support the intermating of the first and second electrical terminal
elements.
Thus, as keying flanges 18 slide in guide channels 20, a portion of leading
edge A, shown in FIG. 2, contacts at least one first sloped wall 22 at a
point B, representatively shown in FIG. 5. Leading edge A is preferably a
square edge to provide edge or point contact for reduced friction at point
B and along first sloped wall 22 as the first and second electrical
terminal elements intermate. Where trailing down ramps 32 are included, a
portion of leading face C thereof, also shown in FIG. 2, contacts at least
one second sloped wall 42 at a point D, also representatively shown in
FIG. 5. Keying flanges 18 are thereby directed down keying slots 24 in a
second direction angularly related to the first direction by control angle
30, which is preferably an acute angle, as shown in FIG. 5. As terminal
pins 34 and terminal pin receptacles 36 are also preferably set at control
angle 30, terminal housing 12 continues down keyed slot 24, preferably
until seating surfaces 38, 40 mate, intermating terminal pins 34 and
terminal pin receptacles 36 and completing the connection.
The step of inserting may be accomplished with the aid of a mechanical
device, such as the cam lever mechanism 60, previously discussed above.
Finally, the method may further include the step of uncoupling terminal
housing 12 from receptacle frame 14, which may also be accomplished with a
mechanical device, such as cam lever mechanism 60.
While certain representative embodiments and details have been shown and
described for purposes of illustrating the invention, it will be apparent
to those skilled in the art that various changes in the article, system
and method disclosed may be made without departing from the scope of the
invention. For example, the position, shape or orientation of the keying
flanges and trailing down ramps may be further varied, as may the shape of
the connector itself. Further, the design of the force applying means may
be vary, yet perform the desired function to achieve the purposes
disclosed herein. Thus, these and other features of the invention may be
varied, without departing from the scope of the invention which is defined
in the appended claims.
Top